Reinforced container



April 13, 1965 P. WASYLUKA R'INFORCED CONTAINER 2 Sheets-Sheet 1Filedec.

NVENOR; Y R41/L mm/KA April 13, i965. P vwAsYLuKA 3,178,093

REINFORCED CONTAINER 2 Sheets-Sheet 2 Filed Dec. 5l, 1962 INVENTOR.,DAU/ WASH. UKA

. arranged wall relation.

United States This invention appertains to reinforcing means forshipping containers or cartons made from bendable materials andparticularly to shipping containers or cartons made from solidlibreboard which employ a rigidificd corner structure.

Various types of shipping containers are employed for use in storing andtransporting bottle goods such as soft drinks and the like. Oneparticular typc of shipping container constructed of solid tibrcboard orpaperboard i: `employed to store and transport 24 twelve ounce bottlesof beverage. Quite often fibreboard shipping containers of this type arcof open top construction. that is no top closure member is provided.Such containers are most t ften provided with handhole openings in eachend wall to facilitate manual handling. When such containers are lift'-ed manually, due to the inherent flexibility of the breboard material,reinforcing means must be provided along the upper edge of the containerto prevent liexure and failure of the container end walls. Furthermore,it lias been found that such containers absent extrinsic reinforcingmeans, tend to flex or distend out of their nefmal and properrectangular shape, which interferes with highly mechanized packaginglines and handling vprocedures Heretofore, it has been found necessaryand desira. le to provide extrinsic reinforcing means such as rela,ively heavy guage wire placed in and Secured to the upper margin of thecontainer to reinforce and rigidify such shipping container. While suchwire reinforcing means satisfactorily strengthens the container for therough usage such a container is subjected to, the use of metallicreinforcing means is often objectionable for several reasons. It isdiiiicult to fixedly secure a wire or similar metallic reinforcing meansinto a container. In addition metallic reinforcing means may be subjectto rust or other deterioration during use. Also in order to salvagt4 thetibreboard container for scrap purposes, metallic reir; 'orcing meansmust be removed and this is accomplished'only with some difficulty.

It is therefore an object of this invention to provide a shippingcontainer of the type described which, by reason of its novelconstruction, is reinforced and rigiditied against accidental liexing ordistortion, without requiring` additional or expensive reinforcing meanssuch as wire and the like. t

it is anotherobject of this invention to provide a shipping container,formed from a foldable blank, which is integrally reinforced andrigidied in open rectangular A further object of this invention is toprovide integral reinforcing means for open top shipping containers inwhich the corner portions are reinforced by a novel conioination ofinwardly bulging corner scores and reinforcing apsin xedly stressed andabutting engagement therewith to effec-t a corner structure in rigidright angular relation.

A desirable embodiment of the invention is shown in the accompanyingdrawings which form a part of the description of the invention.

FIGURE l is a plan view of a container blank embodying the invention;

FIGURE 2 is a fragmentary plan view of the blank partially erected;

FIGURE 3 is a sectional View through lines 3-3 of FIGURE 2 looking inthe direction of the arrows;

Eltlt ice FIGURE 4 is a fragmentary' plan view of the blank showing afurtherstage of erection;

FIGURE 5 is a sectionall view taken along lines S-5 of FIGURE 4 in thedirection of the arrows;

FIGURE 6 is a fragmentary plan view of a blank embodying the inventionshown in a still further stage of erection;

FIGURE 7 is an enlarged sectional view taken along lines 7 7 in thedirection of the arrows;

FIGURE 8 is an enlarged sectional view taken along lines 8 8 in thedirection of the arrows;

FIGURE 9 is an enlarged detail partly in section and partly inperspective of a reinforced corner of the prepared blank shown in FIGURE6.

FIGURE i() is a perspective view of an erected container embodying theinvention, preparatory to sealing the bottom closure;

FIGURE ll is a perspective view of a fully erected container;

FIGURE l2 is an enlarged fragmentary perspective view of a corner of acontainer embodying the invention; and

FIGURE 13 is an enlarged sectional View of a corner of a containerembodying the invention.

The invention is particularly adapted to embodiment in containersconstructed of solid fibreboard or other suitable bendable sheetmaterial having a caliper or thickness of 80 to 90 thousandths of aninch. Conventional fibreboards in this range are comprised of laminatedplies of paperboard and combinations of plies of paperboard with othersuitable flexible materials which are adhesively secured together.Fibreboards in the described range of thickness are quite rigid and mustbe suitably scored in order to fold at sheets of the material intocontainer form.

Fibreboard scoring and resulting folds have distinctive characteristicswhich are utilized in a novel and advantageous manner in the presentinvention. The nature of the scores hcrcindescribed are characterized bya relatively narrow male score which is impressed in the outer surfaceof the libreboard sheet and a cooperative aligned female score on theopposite inner surface of the sheet which is of a substantially greaterwidth. The female score results in a raised crown or bead which extendsoutwardly of the surface plane of the breboard. The regular folding ofsuch a score results in a fold line wherein the male score is disposedinteriorly of the fold and the female score exteriorly thereof. If thedescribed lines of scoring are reversely folded, as generally utilizedirr the present invention, the female score is disposed interiorly ofthe fold so that the protruding bead is amplitied to provide apronounced inward protrusion whereas, the exterior or male side of thescore is free of protrusion and gives a smooth substantially rounded orangulatcd exterior surface. This above described character of the scoreswill be more apparent in reference to the detailed description of thedrawings following.

A blank 20 which embodies a desirable form of the invention is shown inFIGURE l. This blank is die cut from a suitable fibreboard sheet and isscored as described above to provide an arrangement of foldablyconnected panels, flaps and reinforcing members. In this view thescoring is indicated by a pair of closely spaced solid linesrepresenting the male scores and dotted line on both sides of the malescores representing the boundaries of the female scores. Of course, themale and female scores are actually on opposite surfaces of the blank asaforementioned. More particularly the blank 20 ce` scribed in termsapplicable to the container erected therefrom, comprises rectangularside wall panels 21-22 which are arranged in alternating relation withend wall panels 2344. The panels are foldably connected by vertic`a1 3corner scores -27. vThe remote side edge 28 of side wall 21 alsocomprises one end edge of the blank 20. Corner connecting ap 29 isfoldably connected to the side edge of end wall 24 by the cornerconnecting apscore 30. The bottom edge of the wall panels 21-24 isdetermined by bottom flap score 31 which further serves as the hingeconnection of the side bottom flaps 32 associated with the side walls21-22 and thehinge connection vof the endbottom flaps 33 which areassociated with the end walls 23-24.

The top edge of the wall panels 21-24 is determined by top edge score 34which serves as the hinge connection of the reinforcing assembly 35. Thereinforcing assembly is comprised of a multiplicity of .plies forming areinforcing rim which will reinforce the top marginal prised in thepreferred embodiment of side wall inner reinforcing members 36 and endwall inner reinforcing members 37 which Vare foldably connected to theouter side wall reinforcing members 38 and end wall outer reinforcingmembers 39 by the bottom reinforcing assembly score 40. The outerreinforcing members 38-39 are in turn foldably connected to side wallintermediate reinforcing members 41 and end wall intermediatereinforcing members 42 by the subjacent top score 43.

Also shown in FIGURE l, the inner reinforcing members`36-37 each haveend edges 44 which are in spaced relation to the line of the respectivecorner scores 25-27 and'30 by a determined distance which will bedescribed hereinafter. The free edges 44 adjacent the line of the cornerscores 25-27 in part determine slots 45 which are further determined byarcuate edges 46 which extend to the remote boundaries of the femalescores 34 and 40.

The end edge 47 of inner reinforcing member 36 adjacent"r the edge 28 ofthe blank is recessed from said edge 28 an amount substantially equal toone-half the width of a slot 45 except for an arcuate edge portion 48which is disposed substantially adjacent to the near edge'of femalescore 34. The end portion 49 of this inner reinforcingv member 36 isdiminished in vertical height having a free bottom edge 50 disposedsubstantially adjacent the near edge of female score 40. At the remoteedge of the blank, end wall inner reinforcing member 37 is provided witha free end edge 50 which is spaced from the line of the cornerconnecting tiap score in a manner similar to the disposition of edge 47.The ends of the free edge 50 are determined by arcuate portions 51adjacent the remote edges of the female scores 34 and 40 and thenceoutwardly to the edge 52 of the blank thus determining a cutout 53.

Continuing in reference to FIGURE l, the outer reinforcing members 38-39are hingedly connected at their adjacent end edges by corner webs 54.Said corner webs 54 are scored bythe buttress scores 55 in alignmentwith the respective corner scores 25-27 and 30. The end wall" outerreinforcing member 39 adjacent the end edge 52 of the blank is foldablyconnected by the buttress score 55 to a corner connecting tab 56. Theside wall inner reinforcing member 38 adjacent the end edge 28 of theblank has a free end edge 57 which is spaced from the blank edge 28 anamount sucient to accommodate the corner connecting tab 56 in theerected condition of the container. This edge 57 is extended todetermine the end edge of the adjacent side wall intermediatereinforcing member 41. The connected together intermediate reinforcingmembers 41-42 are separated by slots 58 determined by the free end edges59 of the respective members and the top edge 60 of the corner webs 54.The free end edges 59 are substantially aligned with the respective freeedges 44 of the inner reinforcing members 36-37. `15

margin of the container walls 21-24 inclusive.

The end edge of end wall intermediate reinforcing member 42 adjacent theedge 52 of the blank is determined by a free edge 61 in alignment withthe end edge 50 of the inner reinforcing member 37. The wall panels areprovided with handholes 62 as shown in the end walls 23-24.

The successive stages of preassembly of the blank preparatory to formingthe same into rectangular container formation is shown in FIGURES 2through 8 inclusive. In these views FIGURES 2, 4 and 6 show sections ofthe inner surface of the blank 20. Preferably the intermediate, outerand inner members of the reinforcing assembly 35 are successivelyreversely folded or rolled to form a reinforcing rim adjacent the innersurface of the top In the first assembly operation shown in FIGURES 2and 3, the intermediate reinforcing members 41-42 are reverse foldedabout the subjacent top score 43 into atwise relation with therespective outer reinforcing members 38-39. This is followed by a secondfolding operation shown in FIGURES 4 and 5 wherein the reinforcingmembers are successively folded about the bottom reinforcing assemblyscore 40 to bring the members of the reinforcing assembly 35 into mutualatwise relation with each other. After a further successive fold aboutthe top edge score 34 the reinforcing assembly 35 is brought intoflatwise relation with the top margin of the inner surface of the wallmembers 21-24 thus completing the preassembled blank of the invention.It is to be noted in regard to FIGURE 6 that the handhole is adjacentthe bottom edge of the reinforcing assembly 35 bottom score 40.Preferably the reinforcing assembly 35 extends very lslightly into thehandhole to provide a smooth rounded gripping edge. FIGURE 7 is a crosssectional view through line 7-7 of FIGURE 6 and shows the multiplicityof plies of the reinforcing member 35 in fiatwise-relation to the wallmember 24 whereby the top edge of the container is determined by the topedge score 34 and the bottom edge of the reinforcing assembly 35 isdetermined by its bottom score 40. It is well to note in regard to thecross sectional view in FIGURE 7 that variable folds may be obtainedwith reverse folded solid ber scoring. The view is somewhat stylized forpurpose of clarity, whereby it is clearly shown that the scoring andfolding may be adapted to encompass various thickness. For example, in acommercial embodiment of the invention involving a container constructedof solid breboard, the reinforcing assembly 35 bottom score 40 andsubjacent top score 43 are formed by a one-eighths inch thick malescoring bar and threeeighths wide female die. The top edge score,encompassing the four plies of the reinforcing assembly. may be formedwith a three-sixteenths inch male bar and one-half inch female. Thecross sectional view FIGURE 8 drawn through line 8-8 of FIGURE 6/ showsthe continuity of the wall panels 21-24 and corner webs 54 at thecorners of the container. The intermediate and inner reinforcing membersare interrupted as shown by the free edges 44 and 59.

The corner construction is shown more clearly in FIG- URE 9 wherein, forexample, a corner score 25, a male score depression 63 and the femaleside of the score 64 which protrudes inwardly of the container areshown. The male depression 65 of the buttress score 55 is disposedinwardly thereof and the inwardly extending female side 66 of thebuttress score 55 extends further inwardly of the container to. provideafprotrusion or buttress 66 intervening the free end edges 44 and 59. Tofurther implement the amplification of the buttress score 5S resultingfrom the impression of the female bead 64, the buttress score ispreferably formed with the wider scoring bars as previously described inconjunction with the top edge score 34, FIGURE 7. I

FIGURE l0 shows a partially assembled container formed from thepreassembled blank of FIGURE 6 wherein the wall panels 21-24 are formedinto tubular rectangular relation with the reinforcing assembly 35arranged about thetop margins of the container. Completion of theassembly of the container is attained by infolding the end bottom flaps33 and side bottom flaps 32 and securing the same together as shown inFIGURE 11. FIGURES l2 and 13 show details of the corner constructionwherein the free end edges 44 and 59 are in substantially abuttingrelation with the buttress 66 land the male score side 63 of the cornerscore is under tension contributing to the rigid disposition of theadjacent Wall panels in right angular corner relation. In regard to thecorner construction just described, the respective adjacent wall marginsand inner reinforcing members are secured together resulting in theeffect that the corner folds of the container walls and corner webs 54include some 160 to 180 thousandths of an inch of solid fibreboardthickness being folded unitarily. Normally, it is not consideredfeasible to score and fold solid breboard in excess of 120 tbousandthsof an inch yet this is accomplished in the present invention whileattaining an advantageous balance between tensioning the outer surfacesof the fold and inward protrusion of the buttress formation.

The preassembled blank of FIGURE 6 cannot be formed into tubularrelation by connecting the corner connecting ap and corner connectingtab S6 to the remote side edge 2S of the blank and then collapsed in anormal fashion because of the tensioned and buttrcssed cornerconstruction of the container. Therefore, such preassembled blanks arestored and shipped in flattened condition prior to assembly into tubularcontainer formation as shown in FIGURE l0, ln forming the preassembledblank into container formation the corner connecting ap 23 and cornerconnecting tab 62 are inserted between the end margin adjacent edge 2Sof side wall 21 and the end portion 49 of the inner reinforcing me'mber36 whereby the corner connecting tab 56 is disposed in the voiddetermined by the recessed end edge 57 of the outer and intermediatereinforcing members 41-43. The corner connecting flap 23 and tab 56 arethen secured to the said end margins of the wall panel 21 by stitches 67or other suitable means.

As before mentioned the members or plies of the reinforcing assembly aresecured together and to the inner surface of the top margin of thecontainer walls 21-24 inclusive. Adhesive is the preferred securingmeans and may be applied conveniently to the inner surface, that is thefemale score side of the blank, of the intermediate reinforcing members41 and d2 and the outer surface of the outer reinforcing members 38-39.ifhis adhesive pattern permits a roller application of the adhesiverunning continuously of the length ofthe blank with out encounteringinterference with protruding female scores. Other adhesive patterns arepossible depending on the method of the folding operation of thereinforcing assembly 35 but, in any case, it is required that the outerreinforcing members 38-39 be secured to the adjacent surfaces of thecontainer walls 21-24.

While the preferred commercial embodiment oir the invention has beendescribed, it is apparent that vaiious modifications are possible. Inparticular, the succession and direction of the folding of the pliesofthe reinforcing assembly may be altered if the scoring is suitablyaltered to accommodate itself to the consequent thickness required ofeach fold and regular folds and cut scoresitmay be used alternatively orin combination with the descfibcd reverse folds. ln any event, theoutermost ply or member of the reinforcing assembly preferably includesthe corner webs 54 and the reversely folded buttress scores 55, whilethe intermediate and inner plies or members have free end edges adjacentthe buttress when the container walls are folded into tubular relation.

It is to be understood that the embodiments herein described areillustrative and not restrictive, it is also to be understood that theinvention may be susceptible to ernbodiment in other modified forms, andthat all s/uch modifications which are similar to or equivalent heretocome equally within the scope-of the claims next'appearing.

In the claims:

l. A rigidied container having upright wallsl connected by corner scoresand disposed in tubular relation and bottom closure means, the containerformed from a foldable blank andV having a reinforcing assembly foldablyconnected and disposed in flatwise relation to the inner surface of thetop margins of the container walls, the yreinforcing assembly includinginner, outer and intermediate members in hingedly connected relation,the outer members being secured to the respective container walls, saidouter members connected at their end edges by corner webs, the cornerwebs each having a score in alignment with the respective wall cornerscore and with an inwardly protruding bead, the intermediate and innermembers having free end edges adjacent the respective corner web beads,said beads forming a buttress corner structure with the said free endedges, rigidfying the corners in determined angular relation.

2. A rigidied container as set forth in claim l wherein the cornerscores of the upright walls have inwardly protruding bends, said cornerscore inwardly protruding beads being impressed against the alignedcorner web scores amplifying the inward protrusion thereof.

3. A rigidifted container as set forth in claim 2 wherein the corner webscores are of greater width than the wall corner scores to increase theinward protrusion of the corner web score inner beads.

4. A rigidiied container as set forth in claim 3 wherein the foldableblank is comprised of multiple plies laminated together and having acombined thickness in the range of about SO to thousandths of an inchv5.` A rigidied container formed from a foldable blank having side andend wall panels in alternating relation l and connected together bycorner scores, a corner connecting flap foldably connected to one wallpanel side edge by a corner score, the wall panels arranged in tubularrelation; the container including a reinforcing assembly foldablyconnected and disposed in flatwise relation to the inner surface of thetop margins of the container walls and including inner, outer, andintermediate mem- A bers in hingedly connected relation with the innerand intermediate members being provided with free end edges, the outermembers being secured to the respective container walls, said outermembers connected at their end edges by corner webs, the cornerwebsieach having a score in alignment-with the respective wall cornerscore, one outer member having a connecting tab in juxtaposition to thecorner connecting flap, the connecting flap and connesting taboverlapping and secured to the adjacent one of the tubularly arrangedwall panels with the connecting ap and connecting tab between the marginof said adjacent one wall panel and the end portion of the respectiveinner reinforcing member, the respective'outer and intermediatereinforcing members having a recessed end edge to accommodate theconnecting flap and tab.

6/A rigidified container as set forth in claim 5 wherein the corner webscores each have inwardly protruding beads and the intermediate andinner members free end edges at least in part disposed adjacent saidinwardly protruding beads rigidifying the container corners in determined angular relation.

7. A rigidied container as set forth in claim 6 wherein the cornerscores of the upright walls have inwardly protruding beads, said cornerscore inwardly protruding bead being impressed against the aligned comerweb scores amplifying the inward protrusion thereof.

8. A rigidified container as set forth in claim 7 wherein the foldableblank is comprised of multiple plies laminated together and having acombined thickness in the range of about 8O to 90 thousandths of aninch.

9. A rigidified container as set forth in claim 8 wherein the corner webscores are of greater width .than the wall scores to increase the inwardprotrusion of the corner `web score inner beads.

l0. A rigiditicd open top Container formed from a fold- :iblc blank ofsolid tiberboard, the container having upright walls disposed inrectangular tubular relation, tbe walls being foldably connected bycornerscores with inwardly protruding beads, the container including amultiple ply -vin'tegral reinforcing assembly comprising reinforcingmembers hingedly connected to the top margins of the respective wallsand folded in mutual atwise relation and adhesively secured to theinterior of the top mari ginsof each of the container walls, one ply ofsaid reinforcing members including corner webs at cach corner of thecontainer, thc corner webs scored to provide protrudiving beads inalign-ment with the respective corner score protruding beads, theremaining reinforcing members having free end edges adjacent the saidprotruding beads, said beads forming a buttress corner structure withsaid free end edges, rigidifying the corners in determined angularrelation.

References Cited by the Examiner UNITED STATES PATENTS 1,146,115 7/15Weiss. 1,158,130 10/15 Hawkins. 1,198,298 9/ 16 Walter. 2,220,388 11/40Bearnan. 2,474,523 6/ 49 Guyer. 2,752,032 6/ 56 Fish. 2,994,468 8/ 61George et al.

GEORGE O. RALSTQN,` Primary Examiner.

1. A RIGIDIFIED CONTAINER HAVING UPRIGHT WALLS CONNECTED BY CORNERSCORES AND DISPOSED IN TUBULAR RELATION AND BOTTOM CLOSURE MEANS, THECONTAINER FORMED FROM A FOLDABLE BLANK AND HAVING A REINFORCING ASSEMBLYFOLDABLY CONNECTED AND DISPOSED IN FLATWISE RELATION TO THE INNERSURFACE OF THE TOP MARGINS OF THE CONTAINER WALLS, THE REINFORCINGASSEMBLY INCLUDING INNER, OUTER AND INTERMEDIATE MEMBERS IN HINGEDLYCONNECTED RELATION, THE OUTER MEMBERS BEING SECURED TO THE RESPECTIVECONTAINER WALLS, SAID OUTER MEMBERS CONNECTED AT THEIR END EDGES BYCORNER WEBS, THE CORNER WEBS EACH HAVING A SCORE IN ALIGNMENT WITH THERESPECTIVE WALL CENTER SCORE AND WITH AN INWARDLY PROTRUDING BEAD, THEINTERMEDIATE AND INNER MEMBERS HAVING FREE END EDGES ADJACENT THERESPECTIVE CORNER WEB BEADS, SAID BEADS FORMING A BUTTRESS CORNERSTRUCTURE WITH THE SAID FREE AND EDGES, RIGIDFYING THE CORNERS INDETERMINED ANGULAR RELATION.